Manufacture of textile materials



May 1, 1934. w. I. TAYLOR MANUFACTURE OF TEXTILE MATERIALS Filed April 1, 1933 W)LL1AM I TAxe fi ral/fl w ATT OEMEYS duces a yarn of Patented May 1, 1934 MANUFACTURE OF TEXTILE MATERIALS William Ivan Taylor,-

to Celanese Corporation of England, assignm- Spondon, near Derby,

America, a corporation of Delaware Application April 1, 1933, Serial No. 663,941

, In Great Britain April 13, 1932 13 Claims.

This invention relates to the manufacture of textile materials, and in particular to yarns hav-. ing a basis of continuous filaments, but having the appearance of spun yarn, that is yarn made from staple fibre.

In the manufacture of spun yarn from artificial fibres, the usual practice is to cut continuous artificial filaments or waste filaments into comparatively short lengths, for example of 1 to 2 inches or more, and then subject the staple fibres produced to a series of operations appropriate to the length of the fibre, such operations being similar to those accorded to natural fibres such as cotton or wool, including opening, carding, drawing and spinning. These operations represent considerable expense in the production of such yarns, since they involve a relatively slow transformation of the initial fibrous material to a finished yarn.

The object of the present invention is to produce yarn having an appearance similar to that of yarn made from spun fibre while avoiding the necessity for forming continuous filaments into short lengths and spinning the fibres thus produced.

According to the present invention a continuous filament yarn. is subjected while travelling in a surface of rotation to the action of cutting or tearing means which break the continuity of the filaments in the yarn at frequent intervals, so that the resulting yarn has a number of broken ends which give it when twisted the appearone or relatively few of the filaments in the yarn are broken, so that continuity of the bundle as a whole is not interfered with. At the same timethe distribution of the breakages throughout a large number of the filaments in the yarn prosubstantially even character in which the filament lengths are of the same order. The breaking of the individual filaments is carried out in a fairly regular manner so as to impart a uniform appearance along the length of the yarn, and as well as to avoid undue reduction in the strength of the yarn owing to the breakage of the filaments.

Carrying out the cutting or breaking of the filaments during a twisting operation affords an easy method of securing the breaking of filaments in succession, since the cutting may be performed on the yarn while it is rotating under the infiuence of the spindle. At the same time, the applied twist is of assistance in binding in the ends of the severed filaments. Thus, the cutting means may constitute a circular member suitably serrated or itself of an abrasive character surrounding the ballooning yarn and so positioned that the yarn sweeps round the cutting surface of the member.

Not only can the cutting of the filaments be effected at a twisting and winding device such as a cap or ring spinning device, but also at delivery from a twisting spindle, the cutting device being suitably positioned to be engaged by the thread as it passes from the package to the balloon'guide. The invention is, however, of particular importance in enabling a continuous filament yarn to be given the appearance of a spun yarn during its actual production. Thus, for example, the filaments of a yarn of cellulose acetate may be cut as they are being twisted and wound on a cap-spinning device continuously with their production by the dry or evaporative method.

The process according to the invention may be applied to any type of continuous filament yarn, for example yarn of cellulose acetate or other organic derivatives of cellulose, e. g. other cellulose esters, such as cellulose formate, propionate and butyrate, and cellulose ethers, such as methyl, ethyl and benzyl cellulose, yarn of. reconstituted cellulose such as viscose, nitrocellulose and cuprammonium artificial silk and natural silk. It may likewise .be applied to yarns consisting of a mixture of filaments of two or more of the above types. Further, a yarn having broken filaments may be doubled with any type of yarn of a similar or dissimilar nature, whether as regards material or type of constituent filaments or fibres. Again, two or more broken filament yarns may bedoubled together for the purpose of increasing the denier or counts of the yarn and improving the regularity of the yarn, or for any other purpose such as the production of yarn containing filaments having different dyeing properties. Thus, for example, two or more broken filament yarns of cellulose acetate may be'doubled together and one or more of such cellulose acetate yarns may be doubled with yarns, filaments or fibres of natural silk, reconstituted cellulose silk, cotton, or wool, or with any two or more of such yarns.

Where the basic yarn consists of artificial filaments, these may be of a lustrous character, or they may be of subdued or reduced lustre. Again, filaments or yarns of subdued or reduced lustre maybe mixed or doubled with lustrous filaments or yarns, either before or after effecting filament breakage.

The yarns or mixed yarns according to the invention may be used alone or in admixture with other yarns in the production of woven, knitted or other fabrics. For example, the yarns may be introduced into the weft or warp or both of woven fabrics to produce a fabric having the appearance of one constituted wholly of staple fibre "yarns, or having more or less local patterns or effects due to the employment of the broken filament yarns. Similarly, knitted fabrics of all descriptions may contain the yarns either as effect materials or asthe sole or principalconstituent of the fabrics. The invention includes within its scope fabrics or articles made from or containing such broken filament yarns.

By way of example several ways of carrying out the invention will now be described with reference to the accompanying drawing, in which Fig. 1 shows in part-sectional elevation apparatus for the continuous production and treatment of yarn according to the invention;

Figs. 2 and 3 are underneath plan and sectional elevation views respectively of a detail of Fig. 1; and

Figs. 4 and 5 are plan views of alternative details of Fig. 1.

As shown in Fig. 1, filaments 12 extruded from a jet 13 within a spinning cabinet 14 are associated as an untwisted yarn 15 at a guide 16 from which the yarn proceeds through an aperture 17 in the wall of the spinning cabinet 14 to a godet roller 18. The yarn is passed round the godet roller 18 in order to maintain a substantially non-slipping contact therewith, and is fed forward at a substantially constant rate through a balloon guide 19 to a cap spinning device indicated generally at 20, containing a winding bobbin 21, the rotation of which, co-operating with the lower edge of the cap 22, twists and winds the yarn 15 while causing it to balloon about the cap 22 in the known manner.

Interposed between the top of the cap 22 and the balloon guide 19 is a flat ring-like member 25 (Figs. 1 and 2) arranged co-axially with the cap, and so adjusted in height relative to the cap that the ballooning yarn contacts with the lower edge 26 of the inner portion of the member 25. This lower edge is sharply notched or toothed as indicated at 2'7 in Figs. 2 and 3, so as to form a saw-like cutting surface, the teeth of which are inclined towards the approaching yarn, and on contacting therewith sever or break filaments along and round the yarn.

An inclined slot 29 in the member 25 enables yarn newly connected to the bobbin 21 to be passed quickly from outside the member 25 to the cutting surface, and prevents yarn leaving the cutting area during its rotation.

In order to enable the cap 22 andbobbin 21 to be removed without loss of time, the balloon guide 19 and the cutting device 25 are hinged at 28 and 30 respectively near their connection to the spinning machine. A bifurcated extension 31 of the member 25 allows of adjustment of the height of the member relative to the cap 22, in order that different sizes of yarn balloon (resulting for example from the treatment of yarns of different denier, or from a change of bobbin speed or bobbin size, or varying the amount of twist inserted in the yarn), may be accommodated. 1

Alternatively, or in addition to adjusting the cutting surface 26 relative to the cap 22, cutting members of different diameters may 'be used, and it is found that diameters of A", 1 /4" and 2" are suitable for use when treating yarn of 100, 200 and 400 denier respectively, with the cutting surface arranged about half-way between the top of the cap 22 and theballoon guide 19.

The number of notches 27 determines to some extent the number of filament breakages produced. With yarns fed at metres per minute, 104 notches of, say, 1/64" in depth will give up to about 9 outs per inch. Though it does not necessarily follow that a filament is out each time the thread encounters one of the notches, some 40 or 50% of these encounters result in breakages, so that the number of notches required to produce the breakages in, say, 50 to 75% of the filaments can readily be determined. The actual number of breakages per unit length of theyarn will, of course, depend on the number and depth of the notches and the rate of feed of the yarn, that is to say, in the order of 8 or 12 breakageaperinch. Several filaments may be cut at each notch, but it is better from a strength point of view to distribute the breakages fairly evenly along the length of the yarn, and for this reason the notches should be numerous but shallow. The severing or breaking of the filaments results in a number of filament ends projecting from the yarn, and the twist inserted in the yarn by the cap spinning device 20 tends to bind these ends into the body of the yarn, consequently reducing the degree of hairiness or beardiness of the yarn, and preserving the tensile strength of the yarn.

The device shown in Fig. 4 which may substitute the device 25 of Fig. 1 enables variation of the pitch of the cutting notches, and thereby the frequency of cut, to be effected simply and without loss of time. This device comprises two flat, superposed, ring-like plates 32 (the upper only being visible in Fig. 4) held apart by pins 33 33 to house a number of toothed cutting wheels 34 34 (8 shown) which are rotatable about the pins 33 33. The pins 33 l 33 are so positioned that the cutting wheels 34 protrude into the space within the ring 32. The teeth of the cutting wheels 34 34 are similarly graduated and range from a substantially fine to a substantially coarse pitch so that on rotation of the cutting wheels any desired form of cutting tooth may be presented to the ballooning thread, which engages the cutting teeth in rapid succession.

The wheels 34 34 which normally are maintained in fixed position may be arranged so as to present the same or different sizes of tooth to the ballooning yarn at one time, and while shown centrally pivoted could, of course, be eccentrically pivoted, thus enabling the effective diameter of the cutting circle to be varied.

A radial slot 36 similarly cut in both the upper and lower plates 32 enables the yarn when newly connected to the winding bobbin 21 to be passed into the cutting area. By reason ofthe radial character of the slots the cutting device may be used for the treatment of yarns rotating in either clock or anti-clock direction, and in order to prevent the yarn being expelled outwardly, the inner extremities of the slots are formed with small projections 38, 38 which tend to steer the yarn away from the slot should the yarn approach the neighbourhood of the slot while the yarn is rotating.

The cutting device of Fig. 2 is hinged at 39 to enable quick dofiing of the cap 22 and bobbin 21 to be effected, and a bifurcated extension 38 allows of adjustment of height of the device relative to the cap 22 as explained with reference to Fig. 1.

The device illustrated in Fig. comprises a cutting surface adjustable in diameter so as to vary the cutting frequency and which, if desired, may be regulated during the cutting operation. As shown in Fig. 5 a number of bladelike plates 40 (6 shown) having saw-like cutting edges 41 are pivoted at 42 to a fixed ring-like plate 43 and are arranged in underand overlapping formation to form a symmetrical sixsided aperture inside whichthe ballooning yarn rotates. The fixed extremities of the plates 40 are rounded and toothed as indicated'at 44, and engage similar teeth 45 formed in a ring 46 encircling the plates 40. A control handle 47 outstanding from the toothed ring 46 enables the ring 46 to be rotated and by reason of the engagement of the teeth 45 of the ring 46 with the teeth 44 of the plates 40, the plates v40 may simultaneously be moved towards or away from the centre of the cutting area, maintaining at any position a symmetrical aperture. A smaller sized aperture is shown in dotted line in Fig. 5. I

A further ring 48 fixed concentrically about the ring 46 and adapted to remain stationary, is cut short at 49 in order to limit the extent of movement of the control handle 47 of the ring 46. The plates 40 therefore constitute an adjustable aperture, the opening or closing of which provides the correct size of aperture for any particular denier of yarn being treated, and offers a rapid and convenient means for varying the frequency of cutting of the filaments in the yarn.

As explained with reference tothe cutting devices shown in Figs. 2 and 4, the device of Fig. 5 is hinged at 50 to enable the cap 22 and bobbin 21 to be removed without loss of time, and a bifurcated extension 51 enables the device to be secured to the machine, although by reason of the adjustable nature of the aperture, the device need not necessarily be adjustable in height relative to the cap. In threading up a newlystarted yarn, the yarn is passed through the aperture in either single or double formation and is connected to the winding bobbin in the'usual manner.

While the above forms of cutting apparatus have been described specifically with reference to a spinning machine it is to be understood that the use of such cutting devices in conjunction withany form of thread twisting apparatus is within the scope of the invention.

If desired, the roughened yarn may afterwards be passed between fur or felt covered rollers or brushes rotating in the opposite direction to the 1 direction of travel of the yarn in order to lay the beard, or alternatively or in addition to this process the yarnmay be subjected to a gassing or other beard-removing operation after the cutting operation.

What I claim and desire to secure by Letters Patent is:-

1. Process for the production of yarns of filamentous materials, said process comprising rotating a travelling continuous filamentary bundle in a substantially circular path and during such rotation cutting filaments of said bundle at intervals along and round the bundle, in such a manner that different filaments are cut at different points in the bundle so as to. impart a fibrous character to the bundle.

2. Process for the production of yarns of filamentous materials, said process comprising twisting a travelling continuous filamentary bundle by rotating the bundle about its axis in a substantially circular path, and during such rotation cutting filaments of said bundle at intervals along and round the bundle, in such a manner that different filaments are cut at different points in the bundle so as to impart a fibrous character to the bundle.

3. Process for the production of yarns of filamentous materials, said process comprising forming a plurality of artificial filaments, associating said filaments as a substantially twistless bundle, feeding said bundle forward, rotating said bundle in a substantially circular path, and during such rotation cutting filaments of said bundle at intervals along and round the bundle, in such a manner that different filaments are cut at different points in the bundle so as to impart a fibrous character to the bundle.

4. Process for the production of yarns of filamentous materials, said process comprising forming a plurality of filaments of cellulose acetate or other organic derivative of cellulose, associating said filaments as a substantially twistless bundle, feeding said bundle forward, rotating said bundle in a substantially circular path, anddur ing such rotation cutting filaments of said bundle at intervals along and round the bundle, in such a manner that different filaments are cut at different points in the bundle so as to impart a fibrous character to the bundle.

5..Process for the production of yarns of filamentous materials, said process comprising forming by dry-spinning a plurality of filaments of cellulose acetate or other organic derivative of cellulose, associating said filaments as a substantially twistless bundle, feeding said bundle forward, cap-spinning said bundle, thereby causing said bundle to rotate as a balloon, andcutting filaments of said ballooning bundle at intervals along and round the bundle, in such a manner that different filaments are cut at different points in the bundle so as to impart a fibrous character to the bundle.

6. Apparatus for the. production of yarns of filamentous materials, said apparatus comprising means adapted to rotate a filamentary yarn through a substantially circular path, means for feeding the rotating yarn linearly with respect to said means, and cutting means adapted to contact intermittently with the rotating and travelling yarn so as to sever filaments at intervals along its length and thereby to impart a fibrous character thereto.

'7. Apparatus for the production of yarns of filamentous materials, said apparatus comprising a yarn twisting device adapted to rotate a filamentary yarn through a substantially circular path, means for feeding the rotating yarn linearly with respect to said device, and cutting means adapted to contact intermittently with the rotating and travelling yarn so as to sever filamentsat intervals along its length and thereby to impart a fibrous character thereto.

8. Apparatus for the production of yarns of filamentous materials, said apparatus comprising v means adapted to rotate a filamentary yarn through a substantially circular path, means for .150

feeding the rotating yarn linearly with respect to said means, means adapted to surround the rotating yarn, and severing means on said surrounding means adapted to make intermittent contact with the yarn so as to sever filaments at intervals along its length and thereby to impart a fibrous character thereto. I

9. Apparatus for the production of yarns of filamentous materials, said apparatus comprising means adapted to rotate a filamentary yarn through a substantially circular path, means for feeding the rotating yarn linearly with respect to said means, means adapted to surround the rotating yarn and bearing cutting teeth adapted to make intermittent contact with the yarn so as to sever filaments at intervals along its length, and means adapted to vary the frequency of cutting of the filaments.

10. Apparatus for the production of yarns of filamentous materials, said apparatus comprising means adapted to rotate a filamentary yarn through a substantially circular path, means for feeding the rotating yarn linearly with respect to said means, a plurality of cutting devices adapted to surround the rotating yarn, said cutting devices each having a plurality of teeth of different pitch and being so mounted as to present certain of the cutting teeth to the yarn in order to sever filaments at intervals along and round the yarn, said cutting devices being adjustable in order that difierent teeth may be presented to the yarn to vary the frequency with which yarn is cut.

11. Apparatus for the production of yarns of filamentous materials, said apparatus comprising means adapted to rotate a filamentary yarn through a substantially circular path, means for feeding the rotating yarn linearly with respect to said means, means having an aperture therein through which the rotating yarn is caused to pass, and cutting teeth round the periphery of said aperture adapted to contact intermittently with the yarn so as to sever filaments thereof and impart a fibrous character thereto.

12. Apparatus for the production of yarns of filamentous materials, said apparatus comprising means adapted to rotate a filamentary yarn through a substantially circular path, means for feeding the rotating yarn linearly with respect to said means, a plurality of cutting devices adapted to surround the rotating yarn and to contact intermittently therewith so as to sever filaments at intervals and impart a fibrous character thereto, and common means adapted to adjust the effective diameter of said cutting devices.

13. Apparatus for the production of yarns of filamentous materials, said apparatus comprising in combination a dry-spinning cell adapted to produce a continuous filamentary yarn, means for feeding said yarn, a cap-spinning device adapted to receive and to twist and wind said yarn, and cutting means so disposed with respect to said cap-spinning device as to engage the yarn ballooning round the cap and adapted to sever filaments thereof at intervals along its length, and thereby to impart a fibrous character thereto.

WILLIAM IVAN TAYLOR. 

